Shapable protective covers for preventing liquids from flowing into vertical drains

ABSTRACT

Shapable protective covers for vertical drains and other holes to prevent spills and other liquids from flowing therein are disclosed. The shapable protective covers include a backing layer with a malleable shapable core and a pliable, tacky sealing layer. The pliable, tacky sealing layer may be secured to the other layers by a bonding layer adhered to or partially embedded in at least one of the layers. The shapable protective covers may be positioned over a vertical drain such that an exposed surface of a pliable, tacky sealing layer contacts a portion of the surface surrounding the vertical drain, thereby preventing liquids from passing through the drain.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/589,694 filed Jan. 23, 2012, which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to protective covers, and more particularly relates to shapable covers for protecting vertical drains, holes and the like from spills and unwanted liquids.

BACKGROUND INFORMATION

It is often desirable to temporarily close off drains to prevent various liquids from flowing therein. Particularly, when handling hazardous liquids in the vicinity of a drain, such as a storm drain or manhole, it is desirable to temporarily seal off the drain to prevent any hazardous liquid that may be accidentally spilled on the ground from entering the drain. Some known methods of sealing off a drain to prevent the possible ingress of liquids include providing custom fitted rigid covers, utilizing manual or automatic cutoff valves, covering the drain with a flexible material (e.g., canvas) and covering the flexible material with dirt or sand, and utilizing a sheet of polyurethane, vinyls, and other pliable materials to cover the drain. However, these known methods of drain isolation have certain practical limitations to their usefulness.

Utilizing custom fitted rigid covers or cutoff valves requires extensive preparation and installation efforts. Manufacturing a custom fitted cover and/or installing cutoff valves are both time consuming endeavors. Neither a custom fitted cover nor an installed cutoff valve can be easily adapted for use in covering and isolating drains other than the one for which the cover or valve was specifically designed, and they cannot be driven over. Moreover, once a custom fitted cover or cutoff valve is in place in a drain or drain system, neither is readily removable and/or transportable to another location for use.

Utilizing a flexible material held in place by dirt, sand or water to seal off a drain also presents certain problems in that such a covering is difficult to work with and is cumbersome and time consuming to implement in emergency situations. The effective seal surrounding the drain is limited by the dirt or sand utilized to hold the flexible material in place, and is further limited in that the dirt or sand may be washed away or eroded during flooding. In addition, water-filled drain blockers cannot be driven over. Such a drain covering has limited reusability and transportability, and the seal effectuated thereby has little resistance to the shear forces of onrushing liquids.

Utilizing protective covers with pliable, tacky sealing layers provides effective seals on horizontal surfaces. Examples of such protective covers are disclosed in U.S. Pat. Nos. 7,950,075; 8,117,686; and 8,230,530, which are incorporated herein by reference. The inherent adhesion and weight of such covers help to maintain contact with the surface. However, when applied to vertical surfaces, the weight of the covers may not help to improve the seal, and may work against adhesion due to gravity.

The present invention is directed toward overcoming one or more the above-mentioned problems.

SUMMARY OF THE INVENTION

Shapable protective covers for vertical drains and other holes to prevent spills and other liquids from flowing therein are provided. The protective covers may be positioned over a vertical drain such that an exposed surface of a pliable, tacky sealing layer contacts a portion of the surface surrounding the vertical drain, thereby preventing a liquid from passing through the drain. The protective covers of the present invention include a backing layer with a malleable shapable core and a pliable, tacky sealing layer. The sealing layer may be secured to the other layers by a bonding layer adhered to or partially embedded in at least one of the layers.

An aspect of the present invention is to provide a protective cover for installation over a drain comprising a shapable backing layer, a bonding layer attached to the shapable backing layer, and a pliable, tacky sealing layer attached to the bonding layer structured and arranged to block spills from entering the drain.

Another aspect of the present invention is to provide a method of making a shapable protective cover for installation over a drain. The method comprises adhering a pliable, tacky sealing layer to a shapable backing layer that includes a shapable layer at least partially embedded in a polymer layer.

These and other aspects of the present invention will be more apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially schematic isometric view illustrating a shapable protective cover installed over a drain having a vertical portion in accordance with an embodiment of the present invention.

FIG. 2 is a partially schematic side sectional view illustrating layers that are used to form a shapable protective cover in accordance with an embodiment of the present invention.

FIG. 3 is a partially schematic side sectional view illustrating the layers of FIG. 2 after they have been fused together in accordance with an embodiment of the present invention.

FIG. 4 is a partially schematic side sectional view illustrating layers of a shapable protective cover in accordance with an embodiment of the present invention.

FIG. 5 is a partially schematic side sectional view showing layers of another shapable protective cover in accordance with an embodiment of the present invention.

FIG. 6 is an exploded isometric view illustrating layers of a shapable protective cover in accordance with an embodiment of the present invention.

FIG. 7 is an exploded isometric view illustrating layers of a shapable protective cover in accordance with another embodiment of the present invention.

FIG. 8 an exploded isometric view illustrating layers of a shapable protective cover in accordance with a further embodiment of the present invention.

FIG. 9 an exploded isometric view illustrating layers of a shapable protective cover in accordance with another embodiment of the present invention.

DETAILED DESCRIPTION

The present invention provides shapable protective covers which prevent spills and/or other unwanted liquids from flowing into vertical drains or holes. At least a portion of the liquid is prevented from flowing into a drain or hole by the protective cover. The spill or unwanted liquid may be any flowable material such as hazardous liquids, storm water, hydrocarbons, chemicals, debris, dirt, trash and the like which are desired to be kept out of drains and the like. As used herein, the term “drain” means any drain, hole or other opening such as a curb-style drain, a pipe opening or the like through which it is desired to prevent the flow of spills or unwanted liquids. A “vertical drain” is a drain having at least a portion extending vertically such that an upper portion of the drain is at a higher elevation than a lower portion of the drain. For example, a curb-style drain may include a lower portion that is substantially horizontal, and an upper portion that extends upward from the horizontal portion at a 90 degree angle, or any other angle having a vertical component.

FIG. 1 illustrates a shapable protective cover 5 in accordance with an embodiment of the present invention installed over a curbside drain 6 having an opening 8 with horizontal and vertical portions. The cover 5 is shapable such that it maintains coverage over the drain opening 8, including the vertical portion of the opening. The shapable protective cover 5 shown in FIG. 1 is generally square in shape, however, any other suitable shape may be used such as rectangular, round, etc.

As used herein, the term “shapable”, when referring to the protective cover, means that the cover may be bent or otherwise formed into a desired shape that is retained after it has been bent or otherwise formed. At least the bent or shaped portion may be self-supporting such that the shaped portion maintains its shape and does not sag or collapse under its own weight, and does not require support from the drain or surrounding structure to maintain its shape. The shapable protective cover may thus be formed into the desired shape to provide a self-supporting, dimensionally stable cover capable of protecting vertical openings. In certain embodiments, the protective cover is sufficiently malleable such that it can be formed by hand into shape without the requirement of hand tools or other tools.

FIG. 2 is a side sectional view illustrating layers that may be used to make a shapable cover in accordance with an embodiment of the invention. The layers include melt-flowable sheets 10 and 11, a malleable shapable layer 12, and a bonding layer 14. FIG. 3 is a side sectional view of a backing layer 18 formed from the layers shown in FIG. 2 after they are bonded or fused together. During fusing, the melt-flowable sheets 10 and 11 flow through openings in the shapable layer 12, thereby encapsulating it to form upper and lower fused sheets 16 a and 16 b surrounding the shapable layer 12. A portion of the lower fused sheet may be melted or infused into a portion of the bonding layer 14, thereby adhering the bonding layer 14 without completely encapsulating it.

FIG. 4 shows the protective cover 5 after a pliable, tacky sealing layer 20 has been applied to the bonding layer 14. The sealing layer 20 may be applied by any suitable method, such as pouring onto the bonding layer 14 and curing, as more fully described below.

As shown in FIG. 1, the protective cover 5 can be positioned for installation over a curb-style drain 6 with an opening 8 having a vertical portion to prevent unwanted liquid from entering the drain. The protective cover 5 adheres to the surface surrounding the opening 8, forming a seal which is sufficient to prevent the flow of at least some liquid past the protective cover 5. The shapable layer 12 enables the protective cover 5 to conform to the shape of the drain 6 while also supplying support. The pliable, tacky sealing layer 20 creates an effective seal even when the surface surrounding the drain is not smooth. The protective cover 5 may be utilized to cover virtually any type of vertical drain or hole so long as at least a portion of the pliable, tacky sealing layer 20 of the protective cover 5 is sized to extend beyond the outer periphery of the drain opening 8 and form a sufficient seal therearound. In one embodiment, the protective cover 5 can be positioned over relatively large areas, e.g., at least 1 square foot up to 25 square feet or more. The protective cover 5 can also be used to cover drains that have both horizontal and vertical openings, such as curb-style drains with grates in front of them. The shapable protective cover 5 can have a length of from about 1 foot to about 12 feet or more, and a width of from about 1 foot to about 12 feet or more. A protective cover 5 positioned over a drain may be sized at least 2 or 3 inches greater than the length, width and height of the drain.

Both the backing layer 18 and the pliable, tacky sealing layer 20 may resist water, oil and many chemicals making the shapable protective cover 5 suitable for use in many types of work environments, including hazardous work environments. The shapable protective cover 5 may be UV-resistant in order to resist damage when exposed to various environments. The protective cover 5 may be cleaned easily with soap and water and is reusable. The malleable shapable layer 12 allows the cover 5 to be re-shaped many times for use with various different shapes and sizes of drains.

The shapable layer 12 provides structural support to the protective cover 5 in vertical applications. The shapable layer 12 may be made of flattened expanded metal, perforated metal, wire screens, wire cloths, cross-laid metal strips or wires, parallel metal strips or wires, woven metal strips, and the like. Expanded metal may be more malleable than perforated metal, and may be easier to shape by hand. Wire screens and cloths may have an undulating surface due to the associated weaving, and can require a thicker plastic or rubber layer to cover and fuse into the open areas.

The melt-flowable sheets 10 and 11, and the fused layers 16 a and 16 b foamed therefrom, may be liquid impermeable, and made from flexible and durable materials. The melt-flowable sheets 10 and 11 can have tensile strengths at least 25 percent higher than the tensile strength of the tacky sealing layer 18. The melt-flowable sheets 10 and 11 can comprise any suitable material such as natural rubber, synthetic rubber, nitrile rubber or plastics such as thermoplastic olefin, polyvinyl chloride, chlorosulfonated polyethylene and the like. Such materials may include UV-resistant additives as well as any other additives that resist damage when the cover 5 is exposed to various environments. In one embodiment, the melt-flowable sheets 10 and 11 may be made of a composite material. Examples of composite materials include rubber laminated to plastic film, plastic film laminated to mesh, rubber laminated to mesh and combinations thereof The thickness of the melt-flowable sheets 10 and 11 typically ranges from 0.01 to 0.25 inch, while the thicknesses of the fused layers 16 a and 16 b may have a total thickness of from 0.02 to 0.5 inch.

In certain embodiments, the bonding layer 14 may comprise a low-density material used to entangle the backing layer 18 and/or the pliable, tacky sealing layer 20. As used herein, the term “low-density bonding layer” means a deep pile or lofty material having at least one surface comprising entanglement fibers that extend from the layer to provide additional surface area and attachment sites for the melt-flowable sheet 11 and/or pliable, tacky sealing layer 20. The low-density bonding layer 14 may have a density that is typically less than 0.26 ounces per cubic inch, preferably from 0.02 to 0.1 ounces per cubic inch. The low-density bonding layer 20 may have a typical thickness of at least 0.01 inch, for example, from 0.02 to 0.25 inch. In one embodiment, the thickness is from 0.04 to 0.06 inch. The low-density bonding layer 14 typically has a weight per area of less than 20 ounces per square yard, for example, from 1 to 10 ounces per square yard. The low-density bonding layer 14 provides secure and permanent attachment between the shapable backing layer 18 and the pliable, tacky sealing layer 20,

The low-density bonding layer 14 may be non-woven and may comprise entanglement fibers made of polyester, polypropylene, poly(ethylene propylene), polyvinylchloride, fiberglass, nylon, cotton, urethane and the like. In one embodiment, the low-density bonding layer 14 comprises a base or backing layer from which the entanglement fibers extend on one or both sides of the backing layer. For example, the low-density bonding layer 14 may comprise fleece made of polyester and having a thickness of 0.055 inch. The fleece assists in the adhesion of the pliable, tacky sealing layer 20 to the shapable backing layer 18.

In one embodiment, the process of fusing the melt-flowable sheets 10 and 11 through the open areas of the shapable layer 12, and fusing the lower melt-flowable sheet 11 into the low-density bonding layer 14, includes the use of heat and/or pressure to achieve melt flow. The melt flow index of the sheets 10 and 11 should be matched to the press conditions. Enough heat, pressure and dwell time should be used to fill the open areas, and can be determined by routine experimentation. One method includes the use of a hydraulic, heated, platen press. Other techniques include vacuum pressing, hot roll lamination, and extrusion coating. A hydraulic heated platen press may be particularly suitable because higher softening-point thermoplastic films can be chosen to increase temperature resistance, impact strength and resistance to deflection. In certain embodiments, the pressing process may include using uncured rubber sheets, pressing them together, and then curing by vulcanization.

In one embodiment, the bonding layer 14 can be deposited on the surface of the lower melt-flowable sheet 11 through hot air roll laminating, or brought into contact with the melt-flowable sheet 11 before it is cured or cooled so that the fibers or protuberances in the Z direction or the openings or voids in the bonding layer are at least partially embedded within the melt-flowable sheet 11. Once the fibers of the low-density bonding layer are embedded within, or otherwise adhered to, the melt-flowable sheet 11, the rest of the layers of the backing layer 18 can be hot press laminated together. The pliable, tacky sealing layer 20 can then be applied to the exposed surface of the backing layer 18 including the bonding layer 14. As the pliable, tacky sealing layer 20 cures or cools, the bonding layer 14 improves adhesion between the backing layer 18 and the pliable, tacky sealing layer 20.

The pliable, tacky sealing layer 20 is flexible and tacky such that it conforms to irregularities or roughness in the spill surface and adheres to the surface surrounding a drain to thereby provide a seal between the backing layer 18 and surface which reduces or eliminates the flow of spilled liquids. The pliable, tacky sealing layer 20 is made of a different material from the backing layer 18, and can comprise materials such as urethane, polyurethane, polyvinyl chloride and/or silicone. The pliable tacky layer 20 may have a hardness, as measured by a durometer, at least 10 percent less than the hardness of the backing layer 18. In one embodiment, the pliable, tacky sealing layer has a durometer hardness of less than 30 shore A. The pliable, tacky sealing layer 20 can comprise an inherently tacky material or can have a standard tackifier applied to any exposed surface. The pliable, tacky sealing layer 20 can have a tackiness such that it adheres to a surface surrounding a drain or hole to prevent the flow of liquid from entering the drain. In one embodiment, the pliable, tacky sealing layer 20 has sufficient tackiness such that the sealing layer adheres when pressed against a vertical wall. The tackiness of the sealing layer 20 may also be measured by other test methods known to those skilled in the art, such as rolling ball, peel and probe tests. The pliable, tacky sealing layer 20 has a typical thickness of from 0.01 to 2 inches.

In one embodiment, a mixture of various polyurethanes can be used to make the pliable, tacky sealing layer 20. A typical polyurethane mixture comprises from about 50 to about 80 weight percent polyol, and from about 20 to about 50 weight percent isocyanate. The liquid polyurethane is mixed and cured in a manner which gives it a moderate degree of inherent tackiness to all exposed surfaces of the polyurethane material. The molding and curing process creates a substantially smooth exposed surface, which may contain minor undulations. The polyurethane material is soft, yet resilient, and thus may be easily severed by a user with a knife. Surfaces of the polyurethane material which are exposed when a portion of it is severed can also be inherently tacky. While a process is described above for manufacturing polyurethane having an inherent tackiness, one skilled in the art will appreciate that other materials, such as, for example, vinyls, silicones and rubbers, may also be modified to have an inherent tackiness.

FIG. 5 illustrates a shapable protective cover 30 similar to the cover 5 shown in FIG. 4, except the low-density bonding layer 14 is adhered by an adhesive layer 32. The adhesive layer 32 may comprise any suitable adhesive, such as a hot melt adhesive comprising polyethylene, polypropylene, styrene butadiene rubber, styrenes, nylon, or the like. For example, the adhesive layer may comprise polyethylene having a thickness of about 0.002 inch.

FIGS. 6-9 are exploded isometric views illustrating various embodiments of shapable layers in accordance with the present invention. In the embodiment shown in FIG. 6, the shapable layer 12 comprises expandable metal having openings 13 extending therethrough. The shapable layer 12 is sandwiched between the upper and lower heat-fusable layers 10 and 11, with the outer edge or perimeter of the shapable layer 12 extending close to the outer edges of the heat-fusable layers 10 and 11. The shapable layer 12 is thus substantially co-extensive with the upper and lower heat-fusable sheets 10 and 11, except for a small area at the perimeter of the layers 10 and 11.

The embodiment shown in FIG. 7 is similar to the embodiment shown in FIG. 6, except the shapable layer 12 is not substantially co-extensive with the heat-fusable sheets 10 and 11. In this embodiment, the shapable layer 12 is only provided is a selected portion of the cover, thereby providing both shapable and non-shapable areas. Such a configuration allows the shapable portion to be positioned over a vertical portion of a hole or drain, while providing a non-shapable or non-self-supporting region for horizontal portions of the hole or drain. In the embodiment shown, the shapable layer 12 covers approximately one-third of the area of the heat-fusable sheets 10 and 11. However, the shapable layer 12 may be provided in any other desirable proportion, for example, from 10 to 90 percent, or from 25 to 50 percent, of the overall area of the cover.

In the embodiment shown in FIG. 8, the shapable layer comprises cross-laid metal strips or wires 112 and 113. Such cross-laid strips 112 and 113 may provide similar malleable and shapable characteristics as the expanded metal embodiment shown in FIG. 6.

In the embodiment shown in FIG. 9, the shapable layer includes parallel-laid strips 212. The strips 212 may be made of metal, and may be in the form of wires, bars, ribbons or the like. In this embodiment, the cover may be shapable in one axis by bending the cover in a direction perpendicular to the lengths of the parallel strips 112, but may be non-shapable in another axis when the cover is bent in a direction parallel with the strips 112. The cover shown in FIG. 9 may therefore be easily rolled or folded with the parallel strips 212 running in an axial or longitudinal direction with respect to the rolled or folded cover, while maintaining shapable characteristics when the cover is bent or otherwise shaped in a direction perpendicular to the strips 212.

The shapable protective covers of the present invention form effective seals around vertical drains, are generally lightweight, and are capable of quick and easy implementation even for large drains. The durable protective covers are readily reusable and transportable, and may be quickly implemented to seal a drain and/or hole in an emergency situation. The malleable and shapable core enables the protective cover to be formed many times. The protective cover may be implemented for use with a variety of different types and sizes of vertical drains and/or holes, and forms a tight seal around the vertical drain/hole to block out unwanted liquids from entering the drain or hole.

Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention as defined in the appended claims. 

What is claimed is:
 1. A protective cover for installation over a drain comprising: a shapable backing layer; a bonding layer attached to the shapable backing layer; and a pliable, tacky sealing layer attached to the bonding layer structured and arranged to block spills from entering the drain.
 2. The protective cover of claim 1, wherein the shapable backing layer comprises a shapable layer at least partially embedded in a durable polymer layer.
 3. The protective cover of claim 2, wherein the shapable layer comprises metal.
 4. The protective cover of claim 2, wherein the shapable layer comprises expanded metal sheet, perforated metal sheet, wire screen, wire cloth, or cross-laid metal strips.
 5. The protective cover of claim 2, wherein the shapable layer comprises parallel metal strips.
 6. The protective cover of claim 2, wherein the shapable layer is substantially co-extensive with the durable polymer layer.
 7. The protective cover of claim 2, wherein the shapable layer has an area less than 50 percent of an area of the durable polymer layer.
 8. The protective cover of claim 2, wherein the shapable layer is fully embedded inside the durable polymer layer.
 9. The protective cover of claim 8, wherein a portion of the durable polymer layer is infused into a portion of the bonding layer.
 10. The protective cover of claim 2, wherein the durable polymer layer has a thickness of from about 0.01 to about 0.25 inch, and comprises natural rubber, synthetic rubber, nitrile rubber, thermoplastic olefin, polyvinyl chloride and/or chlorosulfonated polyethylene.
 11. The protective cover of claim 1, wherein the bonding layer is a low density bonding layer having a density of less than 0.26 ounces per cubic inch, a thickness of from about 0.02 to about 0.25 inch, and a weight per area of less than 20 ounces per square yard.
 12. The protective cover of claim 11, wherein the low-density bonding layer comprises entanglement fibers comprising polyester, polypropylene, poly(ethylene propylene), polyvinylchloride, fiberglass, nylon, cotton and/or urethane.
 13. The protective cover of claim 1, wherein the low-density bonding layer comprises fleece.
 14. The protective cover of claim 1, wherein the pliable, tacky sealing layer has a thickness of from 0.01 to 2 inches.
 15. The protective cover of claim 1, wherein the pliable, tacky sealing layer has a length of at least 1 foot and a width of at least 1 foot.
 16. The protective cover of claim 1, wherein the pliable, tacky sealing layer has a durometer hardness of less than 30 shore A.
 17. The protective cover of claim 1, wherein the pliable, tacky sealing layer comprises urethane, polyurethane, polyvinyl chloride and/or silicone.
 18. The protective cover of claim 1, further comprising an adhesive layer between the bonding layer and the shapable backing layer.
 19. The protective cover of claim 19, wherein the adhesive layer comprises a hot melt adhesive.
 20. A method of making a shapable protective cover for installation over a drain, the method comprising adhering a pliable, tacky sealing layer to a shapable backing layer comprising a shapable layer at least partially embedded in a polymer layer.
 21. The method of claim 20, wherein the pliable, tacky sealing layer is adhered to the shapable backing layer with a bonding layer. 